Engine reconstruction commences!

Family heads out, wrenching commences

With the family off to the grandparents' for the weekend (thanks everyone!), I set about beginning engine reconstruction.  However, before that could begin, I needed to finish building my "clean room".  I thought about just reserving the garage for engine building, but given my rate of progress, that didn't seem like a good idea.

The clean room complete

It has AC!

Ready to begin

A ding in the cylinder-head mating surface - the next bump in the road. But this piston looks good!

Piston when first disassembled

SAI Pump Wire Insulation

A known weakness, the insulation falls of the wires leading to the SAI pump.  I addressed it by knocking off the old insulation and replacing it with Ancor marine-grade shrink wrap (1/4").  Not only did this shrink wrap seem extra sturdy, but it shrinks to 1/3 it's original diameter.  This allows it to clear the collar on the plug and still shrink tight around the wire.  But next time, I would probably just replace the wires.

Engine Pad Replacement

Out with the old

As is common, my 993's engine pad was in sad shape.  There is no easier time to replace it than when the engine is out...

The Fan/Fan Housing Saga

Broken Blade Tip

At the beginning of my top-end rebuild, I was excited about the opportunity to refinish my decrepit-looking 911 engine cooling fan and housing.  Once they were removed, however, I realized they were both damaged beyond repair.

The Damage

The fan was missing two blade tips, and the fan housing was cracked around the alternator mount.  So I decided to bite the bullet and order both new.  I figured it would at least be easy, but Porsche had something else in store for me...

Porsche 993 Top-End Machine Shop Work

Return Shipment

I am way behind on updating the blog. I shipped the cylinder heads for valve-guide replacements almost three months ago, and they came back the day before my daughter was born (the original deadline for finishing the project - oh well).

Maximum Dis-assembly?

I hope so!  Ella's engine has been torn down to the crankcase, so if much more is done that means a complete engine rebuild.

Here are a few photos to commemorate the occasion.

Porsche 993 AC Belt Size

Properly sizing the AC belt on the 993 seems to be problematic.  I have tried two belts, one of which was barely long enough and the other was impossible to make fit.  I think the problem is two-fold.  First, I think the Porsche spec calls for a belt that is a little too short.  Second, some vendors sell a belt as compatible for this application, but it has a different tooth design and will not fit.

993 Engine Drop: It's Out!

Where'd my engine go?

Ella's engine is out!  It actually came out about three weeks ago, but I'd rather be wrenching than blogging :-).

The process is well documented on pcarworkshop.com and the rennlist 993 forum, and I also purchased the Bentley 993 manual. With those sources already available, I don't have much to add to the technical instructions, but click past the break for some notes on moving the engine around in a home garage and, of course, some photos.

993 Engine Drop: Prework

After reading others' experiences, I realized I would have to upgrade my 993 jacking and jack stand procedure for the engine drop.  The engine drop requires a lot of clearance at the rear!


Click for more photos and my lifting procedure.

FD Motorsport SSK and Goldenrod Install

FDM Goldenrod

Over the Easter weekend, a friend and I installed the FD Motorsports Goldenrod and SSK.  Despite having read many glowing reviews, I was somewhat skeptical that the setup would live-up to the hype.

DFW 993 Meet - January 2014

A simple request to hear some modified 993 exhausts led to quite a 993 meet in Dallas this January...and I missed it.  Fortunately my sister and brother-in-law drove Ella over took some photos for me.

The whole story can be found in this Rennlist post:  http://forums.rennlist.com/rennforums/993-forum/785079-looking-for-fister-users-in-dallas-north-dallas-area.html, but here's the short summary:

1. Dallas rennlist forum member rsabeebe wants to hear some exhaust setups
2. Area 993 enthusiasts get excited and join-in...nearly 30 of us
3. A raffle gets started
4. An ice storm covers North Texas, event gets postponed
5. New date selected when I'm out of town :-(, but at least now Darin from FD Motorsports can fly in.
6. More that 30 993's show up at RAC in Addison

Click past the break for some photos.

Photoshoot, July 2013

It took an ice storm in December for me to get time to process photos taken in July, but that's what happens when a future Porsche driver is added to the family...

One of My Favorite Ella Pictures

Click past the jump for additional shots.

Porsche 993 AC Compressor Replacement

As mentioned in this previous post, Ella's AC compressor was suspected of leaking r-134a refrigerant and needed to be replaced.  The repair quote from the mechanic was absolutely ridiculous, so I felt free to buy tools and equipment as well as the parts. :-D

For an excellent how-to article, check-out http://www.pcarworkshop.com/index.php/993_-_A/C_Evaporator_Replace.  Although the title says "evaporator" replace, it also covers the compressor and the receiver/dryer.  Rather than re-create the DIY here, I made a few small contributions to the article on pcarworkshop. Ella even makes a cameo appearance!

In this post, I will cover some of the special circumstances and considerations from my install.

Porsche 993 AC Bracket Repair

Broken Piece of Porsche 993 AC Compressor Bracket

As I was lifting the AC compressor off its base, I heard something metallic falling into the engine bay.  My first thought was that I had missed a bolt or nut somewhere, but I was very careful about that. I looked down into the engine bay to find a piece of the AC compressor bracket.

You could see from the changes in color along the break that it had been cracked for sometime.  I also know of one other 993 owner who experienced the same issue.

Update: Porsche 993 Fog Light Reconditioning

In preparation for a bumperette delete and taking advantage of a Pelican Parts, I ordered "clear corner" lights for the 993.  Excited to see how they would look, I popped them...and was pretty bummed.

A couple months ago, I painted the inside of the fog lights silver to take care of yellowing plastic (post here).  The fogs look great on their own, but when I installed the clear corners, they don't match color wise.  The fit between the corners and the fogs is not as tight as I would like either.

Porsche 993 Fog Light and Clear Corners

At this point, I have a couple of options:

• Get over it
• Repaint the fog light plastic trying to match the clear corners
• Replace the fogs with one of the brake duct fog light replacements
• Swap clear corners for amber corners

Not sure which way I will go yet.

Grounded!

As summer heated up here in Texas, Ella's AC seemed to be growing weaker.  After one miserable hour driving around Dallas in the summer heat without effective AC, I took her in to the shop.

The Culprit?

The mechanic noted the refrigerant was almost completely depleted, but couldn't find the source of the leak.  He added dye and refrigerant and told me to return if I noticed poor AC performance.  A few weeks later, it was time to head back to the mechanic.

This time, he diagnosed the problem as a leaking seal on the AC compressor.  No problem, except that it would cost $2000 to repair with $1500 in parts alone.  After a quick look at the DIY instructions and a search for parts prices indicating I could get the parts myself for $300-$400, I decided to tackle it myself...

It seems that maybe I got myself into a bit more than I first realized, but that story is for another post. :-)

Porsche 993 Fog Light Reconditioning

Ella's fog lights needed some reconditioning.  The passenger side fog light had been cracked by a large stone, and was very yellow.  The driver side looked much newer -- like it had been replaced once already (hmm...don't remember that in the car's history, oh well...).

Porsche 993 Headlight Overhaul (or Ella's New Glasses)

Ella's headlights were looking a bit tired from the rock chips to the yellow-hued bulbs to the yellowed headlight lenses.  She was ready for a makeover.

Replacing Porsche 993 Third Brake Light Bulbs with LEDs

When I purchased Ella, she was sporting a gap-toothed look on the 3rd (middle, high mounted) brake light.  This is really no surprise as the design uses 24 (yes, you read that right, 24) individual incandescent bulbs.

A quick search on rennlist revealed several others had the same thought I did: replace the incandescent bulbs with LEDs.  Even better, several options had already been tried and validated.  I just followed their lead.  Read on for the details and lessons-learned in my install.

[Update 12-Feb-2016]  I recently noticed that Tore at Bergvill FX is selling a kit to replace these incandescent bulbs with LEDs.  While I haven't tried this specific product, my experience with Tore has been great on other products, and I would use his kit if I was to do this job again.

Ella's 5-year PIP (Porsche Improvement Plan ;-))

My back log of projects is nearly complete, so I started day dreaming of where to go next.  Based off a list I put together a while back, here's my "plan" for the next five years.  The only thing that is certain is that this project that won't go according to plan.  Have suggestions; please leave them in the comments below.